Pressing iron



Sept. 29, 1959 JEPSON ETAL PRESSING IRON 4' Sheets-Sheet 1 Filed April 29, 1955 I INVENTORS 56a 5 m4? JEPso/V AND 5 BY JOSEPH 1.. V/ECEL/ 4 m, 1% W gw ATTORNEYS Sept. 29, 1959 I. JEPSON ETAL PRESSING IRON 4 Sheets-Sheet 2 Filed April 29, 1955 IN V EN TOR.

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Sept. 29, 1959 l. JEPSON ETAL PRESSING IRON 4 Sheets-Sheet 4 Filed April 29, 1955 United States Patent-6 2,906,043 PRESSING IRON Ivar J epson, OakPark, and Joseph L. .Vieceli,-1Cicero,:lll;, assignors to Sunbeam. Corporation,- Chicago; 111:, a corporation-of lllinois Application April; 1955,'Serial No. 504,724 20 Claims. (Cl. SS -J7) The present invention relates generally to pressing irons, and, moreparticularly, to a pressingjron capable of readily being converted toa steam iron so that it may serve equally well asa steam or dry iron.

Generally, irons ofthis typecomprise a water reservoir and a valve mechanism:forcontrolling theflow of water to a steam generating chamber, preferably located in the sole plate, at a rate of flow which allows the water to be flashed almost instantlyinto steam. Hence, this type of steam iron is-conventionally referred to asthe flash type. The generated steam is distributed through the material being ironed or steamedby means of ports or the like which communicate with the steam generating chamber and open onthe ironing surface of thesole plate. Irons of this typeare usually provided. with thermostatic means responsive. to the temperature of the sole plateand adjustable to maintain the soleplate at a selectively controlled temperature, depending upon the material to be ironed.

The size of the water reservoir includedin steam irons now available generally causes the irons-tobe bulky :With the result that such ironsdonot present a pleasingappearance, It would bedesirable toprovide a combined steam-dry iron which is substantially of thesamesize as an ordinary dry' iron while still providing a reservoir of large capacity. Prior efiorts to reduce thesize and bulk of this type of iron have generally involvedan arrangement wherein the componentv elements otthe-iron have been-compactly assembled. However, such an.as-. sembly has generally resulted in considerable heat. conduction through the compacted parts to the handle of the ironand hasmade use of the iron quite uncomfortable. It would, of course, be desirable to providean iron possessing small outsidedimensions comparable to those of the ordinary dry iron While having the component elements organized in such manner that a minimum transfer ofheat occurs between the sole plate and the handle.

In steam irons of the flash type presentlyavailable on the market, the Water reservoir is conventionally spaced directly above the sole plate and below. the handle of the iron. Steam irons of this type customarily in? clude manual means for controlling the flow of water to the steam generating chamber and also include manual means for controlling the temperature of the iron. Thus, in the prior art devices, the supports for the cover shell and the handle are conventionally passed through or attached to the reservoir, and, in addition, the reservoir is provided with numerous openings through .which the flow control mechanism and the temperature control mechanism means are passed. Such a reservoir COI'lStI'UCr tion increases its complexity and cost of manufacture, and at the same time introduces the problems referred to above with respect to the transfer of heat from the sole plate to the handle. Inasmuch as the reservoir itself is normally in closeproximity to the heating .ele-. ments and acts as a radiation means tending to maintain the handle at uncomfortably high-temperatures, it would be desirable to provide a construction of the handle and the shell and the reservoir wherein a minimum-number of heat conducting assembly elements are provided.

In pressing irons of the type described above, a major number of the elements constituting the temperature con: trol means. are generally located directly above the sole plate in the most crowded portion of the iron and usually include an operating arm extending upwardly and into the handle. of the iron in order to facilitatefingertip adjustment 'of the operating temperature. Such an arrangement not onlylimits the size of the water reservoir and introduces additional heat transfer problems, but also results in disadvantages in the operation of the thermostatic swtich conventionally employed in the temperature control means. It wouldbe desirable to provide an iron construction wherein the temperature control means is. arranged to provide for more effective utilization of the space between the sole plate and the reservoir while at the same time preventing the heat transmitted to the reservoir fromadversely afiecting the operation of the thermostatic. switch.

In the operation of irons of the type discussed above, the temperature control means, frequently includes a temperaturedial capableo f being'set to different operating temperatures indicated by suitable indicia on the dial and each corresponding to a particular type of material to be ironed. Frequently, however, as the iron-is used, the'dial'setting doesnot correspond exactlyto the iron temperature, with. the result that improper heat is applied to the material beingironed. Asa consequence, it becomes necessary to provide for occasional calibration of the temperature control means in order to'obtain correlation'between thetemperature dial setting-and the operating temperature of the sole plate: In the devices of the prior art, suchgcalibration has generally been possible onlybyl a substantial disassembly'of the iron, a process whichis'both"laborious-and time'consuming. Therefore, it. would, be desirable to provide for the calibration of. the temperature control means by an adjustment readily 'accessible from the exterior of the iron.

Accordingly, it is an object of the present invention to provide a new and improved iron of the character described above; 7

It. is another object of the present invention to provide a new and improved iron which obviates the above-described disadvantages of the prior art devices.

A further object of the present invention is to provide a newand improved iron embodying a novel structural assembly of the sole plate, water reservoir and handle in order to minimize the heat transferred to the handle.

It is another object of the present invention to provide I over that of conventional sadirons by providing'a compact structural arrangement of the component elements.

It isa further object of the present invention toprovide-novel structure for controlling the operating temperature of the iron.

It is likewise an object of the present invention torprovide for more efiective utilization of the space between the sole plate and the water reservoir in order to increase the capacity of the tank while at the same time providing for more effective control of the operating temperature of the iron.

It-is also an object of the present invention to provide a new and improved iron including a temperature control means'whieh may be calibrated through an adjustment readily accessible from the exterior of the iron.

Theinvention further resides in various structural improvements-and innovations in the device by virtue of which efliciency and simplicity of operation are combined with-low manufacturing cost and sturdiness of operation; of :which structural features may be particularly men tioned thernovel manner. inwhioh the water reservoir' is mounted on the sole plate, the compact arrangement of the temperature and steam controls, the ease by which these controls may be employed, the manner in which the thermostatic control mechanism is mounted on the sole plate, and the improved arrangement of various parts thereby insuring simplicity, minimum transfer of heat to the handle of the iron, ease of assembly and disassembly, and low manufacturing costs.

Further objects and advantages of the present invention will become apparent as the following description proceeds, and the features of novelty which characterize the invention will be pointed out with particularity in the claims annexed to and forming a part of this specification.

For a better understanding of the present invention, reference may be had to the accompanying drawings in which:

Fig. l is a perspective view of a pressing iron embodying the features of the present invention;

Fig. 2 is an enlarged longitudinal sectional view taken substantially along the center line of the iron and showing the flow control valve in the open or on position;

Fig. 3 is a sectional view taken substantially along line 33 of Fig. 2, assuming that Fig. 2 shows the complete structure;

Fig. 4 is a top plan view of the pressing iron of Fig. l with the cover shell and the handle removed and with certain portions broken away better to illustrate the thermostatic control switch and the like;

Fig. 5 is a fragmentary top plan view of the sole plate of the pressing iron of the present invention to illustrate the steam generating chamber and the like;

Fig. 6 is an enlarged sectional view taken substantially along line 66 of Fig. 2, assuming that Fig. 2 shows the complete structure, and with some of the background omitted to simplify the drawings;

Fig. 7 is a fragmentary bottom view of the sole plate of the pressing iron of the present invention to illustrate the steam ports and the steam distributing grooves provided therein;

Fig. 8 is a fragmentary sectional view taken substantially along line 8-8 of Fig. 6, assuming that Fig. 6 shows the complete structure, and illustrates particularly the novel temperature control cam of the present invention; and

Fig. 9 is a circuit diagram indicating schematically the electrical control circuit embodied in the pressing iron of Fig. 1.

Referring now to the drawings, there is shown an embodiment of the present invention in the form of an electrically heated pressing iron 9 comprising a sole plate 10 preferably constructed of cast aluminum, having its bottom surface 101; and its sloping side edges 10a polished in order to present smooth clothes contacting surfaces. The sole plate 10 is heated by an electrical element 11 which preferably is of the sheathed type. Such types of heating element are well-known and generally comprise a helical resistance conductor 12 centrally disposed within an outer metallic sheath 13 and supported in spaced relationship in reference to the sheath by an electrical insulating heat conducting mass 14 formed of a suitable material such as highly compressed magnesium oxide. This latter material has been found to provide the desired insulation and at the same time has sufliciently good heat conducting properties so as not to delay the transfer of heat from the coiled resistor element 12 disposed centrally of the sheath 13 to the sheath and, hence, to the sole plate 10 which it is desired to heat. The sheathed heating element 11 is best shown in Figs. 2, 3, 5 and 6 of the drawings and has a generally U-shaped configuration or is roughly in the shape of a hairpin with the extremities of its legs designated at 11a and 11b, respectively, disposed at the rear end of the sole plate, and with a bight portion 110 disposed at the front or pointed end of the sole plate. Preferably the U-shaped heating element 11 is embedded in the sole plate 10 as it being understood that these terminals are suitably connected to the centrally disposed resistance element 12.

For the purpose of defining a steam generating chamber which is in good heat transfer relationship with the heating element 11 or with the rib 15 in which the heating element is disposed, the front portion of the sole plate 10 is provided with a well or chamber generally designated as 18, which may be referred to as the steam generating chamber. This steam generating chamber 18 is defined within the space bounded by the closed end of the U- shaped rib 15 and a vertical wall or cross-member 19 (Figs. 2 and 5) which extends between and eflectively interconnects the two legs of the U-shaped rib 15. This cross-member 19 is disposed a substantial distance away from the bight of the U-shaped rib 15 so that a very large steam generating chamber is provided, taking up an appreciable portion of the surface area of the sole plate between the legs of the U-shaped heating element 11.

In order that a satisfactory steam generating chamber may be defined which is closed to atmosphere except for the steam exit and Water inlet passageways to be described hereinafter, the adjacent top edge of the rib 15 enclosing the steam generating chamber 18 is provided with a flat ledge or sealing surface designated as 15a and best shown in Fig. 5, which is level with the top of the cross member 19 for supporting thereon a suitable cover or closure 20 for the steam generating chamber 18. The cover 20 is described in detail and claimed in a prior copending Jepson application, Serial No. 468,454, filed November 12, 1954, and assigned to the same assignee as the present application.

Briefly, the cover 20, as best shown in Fig. 2 of the drawings, preferably comprises a three layer construction consisting of ,an upper stainless steel member 20a, an intermediate asbestos member 20b and a lowermost aluminum foil member 200. All three of these members forming the cover 20 have a configuration conforming with the shape of the ledge or sealing surface 15a. The cover 20 is initially bowed so as to have a curvature which is concave downward as viewed in Fig. 2 whereby when drawn into sealing engagement with the ledge 15a by suitable fastening means to be described hereinafter, the cover will be stressed to provide a good seal around its entire periphery in engagement with the ledge 15a and the cross-member 19. It will be appreciated that l the asbestos layer 20b affords the necessary resiliprovides a metal to metal seal with the ledge 15a so that the foil conforms to any unevenness of the ledge. The stainless steel layer 20a in effect provides a backing plate uniformly to transmit the sealing force to the entire periphery of the cover 20. As best shown in Fig. 6, the three layers forming the cover 20 are held in assembled relationship by a cylindrical member 21 performing several functions including functioning as a valve body member of a flow control valve designated generally at 22 for regulating the flow of water into the steam generating chamber 18. Hence member 21 is hereinafter referred to as a valve body member. Specifically, the cylindrical valve body member 21 includes a reduced portion 21a extending through a cooperating opening defined in the cover 20 and through a washer 21b preferably formed of stainless steel. The lower end 21a of the valve body member 21 is then deformed, as

acceptaby 'spi'nning' in order to unite the Washer 215, "th'e'three layers of the cover 20' andthe valve body-member zl into an assembled unitary structure. I

To secure the cover 20 to thesteam chamber 18- in sealing relationship with the'sealing' surface -15a-there are provided a plurality of 5 screws or fastening means 23, there being five such screws employed-specifically designated as 2.3a, 23b,23c,-23d and 232.- These screws extend through the cover'20 and are each secured within tapped openings defined in the'sole pl-ate 10. As illustrated, two screws 23a and 23b are used along the portion of the cover 20 disposed towardthe rear of the iron and are secured within tapped openings 19a formed in enlarged portions at the junction between the crossmember 19 and the'ledge 15a.- Thesc'rew 230 is used along the portion of the cover 20 disposed toward the front or pointed end of the soleplate and engages a tapped opening within a raised portion 24 forming an integral part of the sole plate and having integrally formed therewith rearwardly' extending legs or bathe members 25 which effectively divide the steam generating chamber 18 into a central portion and a U-shaped passageway 26'. The screw 23d engages a tapped opening 27a in a circular boss 27 formed integral with the sole plate 10'and disposed at approximately the center of the steam generating chamber 18. The scr'ew 23e is employed along the portion of the cover 20disposed toward the rear of the iron and is effectively secured within a tapped opening 281; in a raised, somewhat circular'portion 28 forming an integral part of the sole plate 10. The raised portion 28 includes a pair of integral leg portions 28a extending in opposite directions transversely of the steam generating chamber and cooperating with small transversely extending tabs 25a formed-integral with the legs 25 to define passageways in the chamber. By tightening the screw 23.2, the bowed configuration of the cover Ztl'is distorted so as to provide an'eflicient seal along the sealing edge a around thesteam generating chamber 18.

In order to insure that only dry steamreaches the pressing surface of the iron, the water supplied to the steam generating chamber 18 through the valve body member 21 secured to the cover plate and described in detail hereinafter enters the chamber adjacent the forward portion thereof, as is best shown in Fig. 2 of the drawings. The surfaces of the sole plateforming the steam generating chamber are preferably treated as by sandblasting and are coated with a thin coat of inorganic insulating material to provide an appreciable temperature drop at the surface of the steam generating chamber, thereby insuring that the water will wet these surfacesto generate the steam desired. The composition of'such coatings on the surfaces of the steam generating chamber is described in detail in the copending Jepson application Serial No. 192,671 filed October 28, 1950, and assigned to the same assignee as the present invention. Briefly, however, one such coating which has been found to afford satisfactory results in producing a permanent water resistant film may be comprised of a thin solution of commercially available material sold under the trade-name Insa-Lute. The latter substance is a type of ceramic cement that can be dispersed in water to form a solution which when evaporated from the steam generating chamber 18 leaves a white hard residue coating the surfaces of the chamber. The water :supplied to the steam generating chamber through the valve 22 wets the treated bottom of the chamber and is immediately flashed into steam. This steam, which may rcontain some quantities'of moisture, must travel rear- -wardly of the steam generating chamber 18 in the direction-of the arrows shown in Fig. 5 through tortuous passageways defined by the legs 28a and the tabs a .and 'then forwardly through the U-shapedpassageway :along the entire lengthofthe steam generating chamber in order to-reachsteam-outlets which comprise ports 31 located at theextreme forward portion of the steam generating chamber: It .will be apparent that, since the ports 31 are located at the bottom" of the 'U-shaped: passageway 26 near the'bight of the U-shaped heating element 11, -thearea immediately surrounding these ports comprises theho-ttest"portion of the sole plate. The steam outlet ports 31 extend from the'steam generatingchamber 18 and open to the bottom 10b of thesole plate 10 and, due to the fact thatthey are formed at :the bight of the U-shaped' passageway 26'at the extreme forward portion of the steam generating chamber, these, ports are collectively arranged'in a sort of V-shaped configuration.

To obtain distribution of the steam emerging throughports 31 over a substantial areaof the ironing surface,

. the pressing surface of the sole plate 10 maybe pro-.

vided with a plurality of elongated grooves designated at 32 and best shown in Fig; 7 of the drawings; These:- grooves may have any configuration but are illustrated, when considered collectively, as providing "a Y-shaped configuration With the common portion of the Y adj acentthe ports-31 and, as a matter of fact; the latterports respectively terminate in the grooves 32. Thus, the steam emerging from the 'ports 31 is expanded over the material being ironed by'the' grooves 32 "with the result that a substantial area of the bottom 10b of the sole plate is covered with steam.

From the above description, it will be apparent that water enters the large steam'generating chamber 18 near the forward portion thereof and steam emerges from this.

chamber also at a region-near its forward point. Thus, the steam must travel from the forward portion of the steam generating chamber to the rear and then back to the forward portion'in' order to reach the steam outlet openings. To insure removal of moisture in the steam-ere ated within the steam generating chamber while it is mov-' ing from the point'of creation to the outlet ports, means are provided, as described-above, to make the available passages very tortuous. To this end, the steam-flows rearwardly of the steeam chamber, through the tortuous passageways bounded by the legs 28a and the tabs 25a; and enters the U-shaped passageway 26 formed between the legs of the ridge 15 and the legs 25. Due to the fact that the passageway '26 extends immediately adja cent the rib 15 enclosing the heating element 11 the temperature of the steam flowing therethrough is high'with the result that practically all of the moisture is converted to steam. Bafiies'29 are provided in the passageway'26 which, in addition to their function of conducting heat to the center of the steam generatingchamber 18,-partially obstruct the passageway 26 and, hence, serve' as water traps for collecting excess moisture in the steam passing to the outlet ports 31.

To facilitate assembly of a suitable thermostatic control device to be described hereinafter near the rear of and extending beyond the sole plate 10,'the latter is provided with a well generally designated at 34, best shown in Figs. 2 and 4 of the drawings, which is defined between the legs of the U-shaped rib 15 enclosing the heating element 11. The well 34 is bounded at its forward end by a wall 35 extending transversely of the'iron between the legs of the U-shaped rib 15 and is bounded at its rearward end by a vertical wall 36 extending between the legs of the U-shaped rib 15 and having a depressed central section 36a (Fig. 3) for receiving certain portions of the thermostatic control device, as will become evident from the ensuing descriptiom The-wall 35 extends sub stantially parallel to the cross-member 19, thus defining a well or recess 35b in the sole plate for isolating the thermostatic control element from the local temperature effects attendant upon formation of steam within the steam generating chamber 18. Moreover, the wall 35 further includes angularly disposed rear surfaces 35a di verging from the center of the sole plate-10 in order to provide relatively large heat conducting masses integral with the legs of the U-shaped rib 15 in which the heating element 11 is embedded, thereby to effect maximum transfer of heat from the heating element 11 to the center of the wall 35 and to provide for effective operation of the thermostatic control device mounted upon this wall by insuring that the temperature of this wall 35 corresponds closely to the temperature of the ironing surface of the sole plate.

In order to provide a support for the cover shell of the iron to be described hereinafter, the forward tip of the sole plate includes a raised portion 37 which, in ac cordance with a feature of the present invention, constitutes the only portion of the sole plate in engagement with the lower edge of the cover shell. To provide guide means for facilitating assembly of the cover shell on the sole plate, the latter is provided at its rearward extremity with a pair of guide lugs 38 formed with the sole plate on opposed sides of the iron, and, in addition, is provided with integrally formed guide lugs 39 located along opposed sides of the sole plate near the steam generating chamber 18.

In order that the steam generating chamber 18 may be provided with a source of water which is flashed into steam there is provided a water reservoir generally designated at 40 possessing an external shape and dimension such as to prevent the iron of the present invention from appearing unusually large or bulky. The reservoir 40, although having relatively small external dimensions, provides a relatively large water reservoir to insure an ample supply of steam for a considerable ironing period. As best shown in Figs. 2, 3, 4 and 6 of the drawings, the reservoir 40 preferably is formed from a pair of sheet metal stampings comprising a bottom wall 41 and a hollow cover portion 42. The cover portion 42 is in the form of an inverted container and includes an outwardly extending flange 42a along its entire peripheral edge in intimate engagement with a flange 41a extending around the entire periphery of the bottom wall member 41. The engaging portions of the flanges 41a and 42a on the members 41 and 42 are joined together by rolling a lip of the flange 41a over the flange 42a and thereafter effecting a seal between the overlapped portions of the flanges, as by welding or brazing, in order to provide a suitable watertight reservoir, as best shown in Fig. 6 of the drawings. To provide space for the operation of the thermostatic control device to be described hereinafter, the bottom wall 41 of the tank or reservoir 40 is also provided with a raised portion 41b which may be placed therein by a suitable stamping opera-tion.

For the purpose of accommodating mechanical linkage for operating the thermostatic control device carried on the sole plate 10 below the water reservoir 40, the latter is provided with a passageway 44a extending therethrough, as best shown in Fig. 2 of the drawings. The passageway 44a is defined by a tubular member 44 which extends through the forward portion of the reservoir and has its upper and lower ends respectively sealed to the top and bottom members 42 and 41 defining the reservoir 40 so as to insure a sealed tank without danger of leakage of water adjacent the passageway 44a. The tubular member 44 includes a guide flange 44b defined near the lower portion thereof and including a rectangular opening therethrough for preventing rotation of certain movable means described hereinafter passing through the passageway 44a. In addition to the passageway 44a through the reservoir 40, there are also provided a pair of vertically aligned openings in the reservoir designated respectively by the reference numerals 45 and 46 and shown in Figs. 2 and 6 of the drawings. The opening 46 is defined by a circular lip 47 extending upwardly from a circular depression 47a in the upper wall 42 near the front of the iron and is adapted to be aligned with a chamber formed in the handle of the iron in a manner to be explained more fully hereinafter. The opening 45, on the other hand, is defined in the bottom wall 41 in vertical alignment with the opening 46 and also in vertical alignment with the valve body member 21 carried on the cover 20 .of the steam generating chamber 18. This opening 45 is formed at the bottom of a somewhat circular indentation 410 in the bottom wall 41 having a flat circular bottom portion as is clearly shown in Fig. 6 of the drawings, thereby to facilitate proper alignment of the tank and the sole plate 10 during assembly thereof. The water inlet valve 22, comprising the valve body member 21 and a vertically extending needle valve member 50, is provided to control the flow of water from the reservoir 4G to the steam generating chamber 18 disposed below the inlet valve 22. The valve body member 21 comprises. a substantially fiat upper surface for engagement with the flat circular portion of the indentation 410 and further includes an elongated body portion for spacing the water reservoir above the sole plate a considerable distance in order to reduce the amount of radiated heat from the heating element 11 and the steam generating chamber 18 absorbed by the water reservoir.

For the purpose of providing a path for the flow of water through the inlet valve 22 from the water reservoir, the valve body member 21 includes a centrally disposed longitudinal passageway extending therethrough. Actually, as will be observed by reference to Fig. 6 of the drawings, the passageway through the valve body member 21 comprises three bores or openings of gradually increased diameter going from the bottom to the top of the valve body, these bores being designated as 51, 52 and 53. The smallest of these bores 51 which defines a metering orifice extends centrally through the reduced portion 21a of the valve body and is adapted to be opened and closed by selectively raising and lowering the needle valve element 50 in a manner to be described in detail hereinafter. In order to prevent chattering of the needle valve element 50 during the warm-up period of the iron when the temperature of the sole plate is being raised to the proper value, the orifice 51 is placed as close as possible to the bottom of the steam generating chamber 18. To provide a seating surface for the needle valve element 50, the valve body member 21 includes a conically-shaped wall or valve seat 54 tapering downwardly and interconnecting the bores 51 and 52 near the lower end of the valve body member. The bore 52 is dimensioned loosely to receive the lower end of the needle valve element 50, while the largest bore 53 is internally threaded for the purpose of accommodating an externally threaded portion of reduced diameter defining a hollow screw or fastening means 55 which is adapted to be inserted through the opening in the bottom wall 41 of the water reservoir 46,

The hollow fastening means includes a longitudinal centrally disposed opening 55a coaxial with the openings 51, 52 and 53 in the valve body member 21 and further includes a screw head 55b having a screw driver engaging slot 550, best shown in Fig. 2, whereby a screw driver inserted through the opening 46 in the top cover plate 42 of the water reservoir 40 may be employed when assembling the tank on the valve body member 21, which is done in a simple manner before the handle of the iron and the component elements housed within this handle are assembled. Thus, it will be observed that in assembling the water reservoir to the valve body member 21, the fastening means 55 is passed through the opening 45 and is threaded into the bore 53 until the screw head 55b engages the upper surface of the indentation 410 in the body wall 41, thereby to hold the water reservoir 40 in fixed position between the upper surface of the valve body member 21 and the lower surface of the head 55!). Effectively, therefore, the valve body member 21, in cooperation with the fastening means 55, performs four separate functions in that: (1) it serves as a valve seat for the needle valve element to be described in greater detail hereinafter; (2) it provides suitable means for fastening the tank or reservoir 40 to amass sole plate or, more particularly, to the 'cover'pla'te 20"attachedto the sole plate; (3) it provides a means,- inaddition to the fastening means 23 previously described, for holding the three layers of the steam generator cover 20*inassembled relationship; and (4) it spaces the water 1 reservoir 40 above the sole plate 10 and steam generating chamber 18 by a distance sufiicient to reduce the radiated heat absorbed by the tank.

It will be appreciated that during an ironing operation the iron is moved backwardly and forwardly in contact with the articles or goods being ironed, with the result that the water in the water reservoir 40 Will tend to rush from one end thereof to the other. To reduce to a minimum such movement of the water and consequent splashing thereof out of the reservoir 40, there is provided a baffle plate 56 best shown in Figs. 2 and 6 of the drawings. This baffle plate is described and claimed ina copending Jepson application Serial No. 410,363 filed February 15, 1954, and assigned to the same assignee as the present application and is also described in the parent case 'of this copending application now Jepson Patent No. 2,690,623 granted October '5, 1954,

and'also assigned to the same assignee as the'present application. Briefly, the baffle plate 56 extends in a diagonal manner substantially across the interior of the reservoir 40, and has its upper end mounted adjacent the rear surface of the tubular member 44 and its lower edgedisposed considerably to the rear of this point and secured to the bottom wall 41 of the reservoir. ings defined between the periphery of the batfie plate 56-and the walls of tank or reservoir 40 (see Fig.6) permit the flow of water between the two chambers formed in the interior of the reservoir 40 on opposite sides of the baffle plate 56, thereby to maintain uniformity oflthe Water level in these chambers. With this arrangement there is a tendency for the water in its movement due to the back and forth motion of the iron'to move in'a circular pattern in the chamber formed at the forward end of the reservoir 40 in order to prevent splash ing of the water out of the upper opening 46 in reservoir 40.

In' addition to the valve body member 21 for main taining the reservoir 40 in elevated position above the sole plate 10, there is provided an additional supporting means in the form of a substantially U-shaped bracket generally designated at 57 and best shown in Figs. 2, 3, and 4 of the drawings. This bracket includes a horizontal portion 57a defining the bight of the U which has its central depressed portion 57b bent to conform to the shape of the recess defined by virtue of the depressed central section 36a at the rear of the sole plate 10 as clearly shown in Fig. 3 of the drawings thus forming a somewhat channel shaped piece extending transversely of' the iron. This bracket 57 is secured to the rear portion of the sole plate 10 by means of suitable screws or other fastening means 59 which extend throughopenings in the bight portion 57a of the bracket 57 into engagement with tapped openings defined in the wall 36 of the sole plate. To minimize heat transfer from the sole plate 10 to the shell support bracket 57 each of the screw receiving openings in the bight portion 57a of the bracket 57 is surrounded by a plurality of spaced indentations 58] as shown in Fig. 4 of the drawings which effectively form pin-like projections protruding downwardly from bracket 57 and grouped around each mounting hole, thereby to space the shell support bracket 57 above the sole plate 10.

For the purpose of supporting a thermostatic control device to be described hereinafter, the portion 57b of the bracket 57 has formed integrally therewith a rigid support arm 57c extending rearwardly from the back edge of the sole plate 10 and including an offset end portion 57d as best shown in Figs. 2 and 3 of the drawings. To facilitate attachment of a closure plate extending rearwardly from the sole plate 10 the offset end portion57d is'provided with a tapped openingtherein:

Open-' Forthedual ur esebr supporting the covr shatterthe iron to be described hereinafter and of-supportingtlie end of the water reservoir disposed toward the rear ofthe iron, the bracket 57 includes a pair of spaced legs-57E extending vertically and upwardly from the horizontally disposed portion 57a. To provide support for the end of the water reservoir 40, the vertical legs 57e eachim clude an integrally formed horizontally extending tab "57) forengaging and supporting the undersurface of the flange joining the top and bottom wall members 42 and 41 forming the water reservoir 40; The two spaced; horizontally aligned tabs 57 are formed intermediate the upper and lower extremities of the legs 57e and; hence, serve to hold the rearward end of the reservoir-40 above the sole plate 10. It will be observed that the spaced tabs 57 and the valve body member 21 con stitute the sole supporting means for the water reservoir 40and, as previously mentioned, function to space this water reservoir above the sole plate 10by a sufiicient distance to reduce the effect of the heat radiated'frorn' the sole plate to the tank 40. The upper end of each of the support legs 57a is provided with a rearwardly extending horizontal projection 57g having an opening 60 therethrough for facilitating assembly of the cover shell of the ironuponthese projections 57g.

To provide means for selectively controlling andmain taining the temperature'of the sole plate 10 at anydesired temperature, there is provided a temperature re-' sponsive control device generally designated at 70 and best shown in Figs. 2, 3 and 4 of the drawings. This device may comprise any well-known temperature respon-- sive device, but it must be capable of being accommodated within a relatively small space between the upper surface of the sole plate 10 and the bottom of the waterreservoir 40. In accordance with the present invention; the temperature responsive control device 70 is supported. so that a substantial portion thereof extends rearwardly of the rear wall 36 of the sole plate 10. Thus,'the ther-' moresponsive control device 70 should preferably be am elongated assembly extending beneath the water reservoir" 40 and facilitating the use of a reservoir containing a large volume of water without appreciably increasing'the out-- side dimensions of the iron. Referring now to the draw'--' ings, the thermoresponsive control device 70 is essentially a subassembly including a supporting frame, a bimetallic element, a control switch, and numerous other necessary elements to be described in detail hereinafter. The sup' porting frame is designated generally by the reference numeral 71 and includes an elongated rectangular frame bars 71a and is provided with suitable openings for receiving fastening means 72 which threadedly engage tapped openings defined near the center of the wall 35, thereby firmly supporting the frame 71 which extends rearwardly from the wall 35 and actually beyond the endof' the rear of the sole plate 10. I

To provide the desired temperature control, the assemblyconstituting the thermoresponsive control device includes a bimetallic element 73 which is preferably spotwelded or otherwise secured to the underside of the cross bar 71b so that when the cross bar 71b is secured to the wall 35 of the sole plate 10' by the fastening means 72,- a portion of the bimetallic element 73 is in intimate heat exchange relationship with the sole plate 10. The bimetallic element 73 is thus secured in cantilever fashion: and extends rearwardly of the Wall 35. For the particu lar design disclosed in the drawings, the highexpansiorr side of the bimetallic element 73 is on top so that as the temperature of the sole plate rises the bimetallic element deflects downwardly. Preferably there is securedtoth'e free'end of the bimetallic'element 73 a contact actuating 11 member 74 which is formed of a suitable insulating material such as a ceramic and which is preferably riveted or otherwise secured to the free end of the bimetallic element 73.

As was pointed out above, the mass of the wall 35 and tapered side portions 35a is sufficiently large to insure accurate correlation between movement of the bimetallic element 73 and changes in temperature of the sole plate 10. Also, to prevent any temperature drop in the sole plate by virtue of the steam generating chamber 18 from interfering with accurate temperature control, there is provided the insulating well 35b described above between the steam generating chamber 18 and the wall 35, which provides an elfective heat barrier.

The temperature responsive device 70 further includes a pair of relatively movable contacts 76 and 77, which are the contacts of a suitable control switch. The contact 76 may be considered the stationary contact, since it does not move in response to operation of the bimetallic element 73. This is somewhat of a misnomer, however, since it is selectively movable, as will become apparent from the following description, to adjust the temperature setting of the pressing iron of the present invention. The contact 77, on the other hand, may be considered the movable contact, since it is adapted to be moved in re sponse to deflection of the bimetallic element 73.

For the purpose of supporting the relatively movable contacts 76 and 77 as a part of the subassernbly 70, there is provided a stack of interposed insulating and conducting members, generally designated at 78, which stack is supported by a rivet 79 from a rearward extension of the cross bar 71c As illustrated, this stack comprises as the bottommost element thereof an insulator 80 which is disposed immediately above the cross bar 710. Resting on this insulating member 80 is a conducting member 81 having electrically connected thereto a flexible arm 82 to which is secured the movable contact 77. The conducting member 81 is provided at one edge with an integral upwardly extending conductor 31a serving as a bus bar for electrically connecting one terminal of the switch comprising contacts 76 and 77 to the heating element 11. Above the flexible arm 82 is an insulating layer 83. Immediately above the insulating layer 83 is a conducting member 84 which effectively provides an insulated support for an upwardly extending conductor 84a to electrically connect one side of the sheathed heating element 11 with a suitable source of power. Thus, the conducting member 84 is included in the subassembly to provide a suitable support for certain electrical connections. Disposed above the conducting member 84 is an insulating layer 85, which layer separates the conducting member 84 from a conducting member 86 electrically connected to a flexible contact support 87, which flexible support acts as a hinge for a contact supporting member 88 formed of rigid material and suitably supporting the relatively stationary contact 7 6. The rigid contact support 88 is provided with a rigid extension 88a, the purpose of which will become apparent from the following description. The conducting member 86 is provided with an integral bus bar extension 86a for permitting an electrical circuit to be made with a suitable power conductor to be described hereinafter. Also, the conducting member 86 is provided with an extension 861) which has a downwardly directed portion engaging cooperating notches in insulating layers 83 and 85. Likewise, the insulating layers 83 and 85 are provided with notches to receive bus bar extensions 81a and 84a, thus providing an assembly in which the relative parts are prevented from rotating even though held in assembled relationship by a single rivet 79, which, of course, is suitably insulated from the conducting members by conventional insulating sleeves.

For the purpose of preventing initial temperature overshoot of the sole plate when first connected to a source of electric energy and to improve the load characteristic,.thethermoresponsive control device 70 in cludes a compensating thermostat, designated by the reference numeral 89, which is illustrated as a short plate riveted or otherwise secured to the end of the flexible switch arm 82 and extending into the path of movement of the contact actuating element 74. The compensating thermostat or bimetallic element 89 has its high expansion side disposed above the low expansion side so that an increase in temperature will cause it to deflect downwardly. Since it is not in good heat transfer relationship with the sole plate '10, it will not deflect as rapidly initially as the element 73 until the ambient temperature of the iron has increased. Thus, as the iron heats up and the bimetallic element comprising the compensating thermostat 89 deflects, a greater deflection of the bimetallic element 73 than is initially required is necessaryv to interrupt the electrical circuit at the switch contacts '76 and 77.

The subassembly 70 defining the thermoresponsive control device additionally includes means for selectively controlling the position of the stationary contact 76 and thereby selectively controlling the temperature of the sole plate 10. As illustrated, there is provided a lever 90 pivotally supported as indicated at 91 between the side arms 71a of the frame '71. This lever 90 is illustrated as including a frame portion 90a disposed between the arms 71a of the frame 71 and having a platform 90b extending beneath the extension 88a of the rigid contact support 88. Pivotal movement of the lever 99 causes relative sliding movement between the extension 88a and the platform 9% of the lever 90. Since the rigid contact support 38 is electrically connected to contact 76, there is interposed for electrically insulating purposes between the rigid extension 38a and the platform 9012 a suitable layer of insulating material 92, such as glass laminated with silicone impregnation or the like. Preferably the portion of the extension 38a engaging the insulating layer 92 is rounded as indicated at 38b. This layer 92 is secured to platform 9% in any suitable manner as by clamping tabs 93 illustrated in Fig. 4 of the drawings. The lever 96 has a rigid elongated extension 900 which extends forwardly of the sole plate beneath the reservoir 40, and has a flat actuating portion 90d which is disposed directly below the passageway 44a described above. The resultant forces acting on the rigid contact support 88 bias the same downwardly into engagement with the insulating layer 92 thus holding the lever 90 somewhat in the position shown in Fig. 2 of the drawings. It will be appreciated that if a downward force is applied to the surface 0d of the lever 90, the so-called stationary contact 76 is moved upwardly away from the movable contact 77 to a position which, even with a cold iron, is out of contact with contact 77, or, in other words, to the open switch position. When no external force is applied to the lever 90, however, the switch comprising the contacts 76 and 77 is closed when the sole plate It is cold. It will be appreciated that in the manufacture of the pressing iron of the present invention, the subassembly comprising the thermoresponsive control device discussed above is manufactured as a separate unit and then secured to the sole plate 10 by screws 72 as one of the first assembly operations. The stack of superimposed insulating and conducting members, generally designated at 78, extends beyond the rear wall 36 of the sole plate 10.

In order electrically to connect the temperature reat this intermediate point with a tapped opening to receive a suitable screw 96 extending through one end of 'one arm of the L-shaped conductor 94. The other arm of the L-shaped conductor 94 is welded or otherwise electrically connected to the terminal 16 of the sheathed heating element 11. Similarly, the L-shaped conductor 95-is electrically connected as by a screw 97 with the extension 81a of the conductor 81, which is electrically connected to the flexible switch arm 82 supporting the contact 77. The other end of this L-shaped conductor 95 is welded or otherwise electrically connected'to the terminal 17 of the sheathed heating element 11.

The electrical circuit described in detail above is clearly shown in the schematic circuit diagram of Fig. 9 of the drawings. It will be appreciated that with the abovedescribed arrangement a switch with relatively long lever arms can be employed in a small space which provides an initially more accurate switch and in which the percentage error due to contact wear is very small.

It will be apparent that the upper surface of the sole plate 10, including the cover 20 of the steam generating chamber and the fastening means 23 as well as the thermoresponsive control device 70 and the tank 40, do not present a very attractive appearance. Therefore; to present a more pleasing appearance, there is'preferably provided a suitable cover shell 100. This cover is-of somewhat inverted dish shape, having a configuration in some respects very similar to the shape of the sole plate 10 but extending a considerable distance beyond therear wall 36 thereof. To provide an opening for filling the water reservoir 40 and to provide a passageway through which the flow control mechanism extends, the upper surface of the cover shell 100 includes a circular opening 101 near the forward end of the iron. The boundaries of the opening 101 define an internal flange forencircling the lip 47 when the cover shell 100 and tank 40 are assembled to the sole plate. To provide an opening in alignment with the passageway 44a in the water reservoir 40 for the purpose of accommodatinga suitable force transmitting member to actuate lever 90 the cover shell 100 further includes a small opening 102 in its upper surface adjacent to and somewhat rearwardly of -the larger opening 101.

14 the bus "bars or connectors 84a and *86a extendfor-corF nection with a suitable power cord described hereinafter. In order to enclose this housing section to the rear of the sole plate 10, there is provided a suitable closure plate 107 which is adapted to besecured to the offset end por tion 57d formed integrally with bracket 57. To this end; the closure plate 107 is provided with an embossedpor tion'having an opening therein in alignment with the tapped opening in the offset portion 57a for the purpose of receiving a mounting screw 108 extending through these.

aligned openings. To provide an enclosed structure possessing an attractive external appearance, the closure plate 107 includes a flange -107a' extending around its three exposed peripheral edges, with the fourth edge of this closure plate being disposed adjacent the heel of the sole plate 10. The upper edge of the peripheral flange 107a at the rear of the closure plate-107 is adapted to engage the lower edge of an indentation 100a defined in the heel of the cover plate 100'. The remaining portions of the peripheral flange 107d on the closure plate are spaced a small distance from the lower edge of the rear wardly disposed portion of the cover shell100 in order to effect a minimum'transfer of heat between these two For the purpose of securing the rear of the cover shell 100 to the sole plate 10 or more specificallyto the support bracket 57 attached to the sole plate 10, there are provided suitable fastening means 104 such as mounting screws extending through openings 60 in the horizontally extending end portions 57g of the bracket 57 and aligned openings in the top rear of the cover shell 100. These screws threadedly engage suitable tapped openings defined in a handle 105 of the iron to be described herein after thereby securing not only the rear of the cover shell 100 butalso the rear of the handle to the sole plate 10.

In accordance with a particular feature of novelty of the present invention, the length of the legs 57:: of the unitary support bracket 57 is sufficient to support the cover shell 100 in elevated position with its lower edge slightly above the sole plate 10. Thus, when the cover shell is assembled upon the iron its forward tip rests upon the small raised portion 37 formed at the extreme for- Ward'end of the-sole plate but the remainder of the lower edge of the cover shell is disposed a slight distance above the sole plate 10 in order to effect a minimum transfer of heat between the sole plate and the cover shell. Moreover, it will he recalled that the transfer of heat between the sole plate and the support bracket 57 for the cover shell 100 is minimized by the spaced pin like projections 58 located between the bracket 57 and the rear wall 36 of the sole plate 10.

The portion of the cover shell 100 extending beyond the heel of the sole plate 10 provides a housing affording access to the fastening means 104 for securing the handle 105 of the pressing iron to the support bracket 57 in the manner described above and for other assembly operations of this nature. The cover shell also includes near the rear thereof a fairly large opening 106 through which elements. 7

From the foregoing explanation it will be observed that the unitary support bracket 57 performs at least four separate functions'in that: (1) it supports the cover shell in elevated position above the sole'plate; (2) itaids in supporting the switch assembly 70; (3) it provides a supporting means for the closure plate 107; and (4) it supports the rearwardly disposed end of the water reser-' voir 40 in elevated position above the sole plate 10. The simplicity of construction and the multiplicity of func tions performed by this unitary support bracket constitute an importantfeature' of the present invention.

So that an operator may manipulate the pressing irondescribed thus far, there is provided the handle "re-: ferred to above preferably formed .of a molded insulating material such as one of the many synthetic resins capable of withstanding relatively high temperatures in the neighborhood 'of 275 to 300 degrees Fahrenheit. The handle 105 is of substantially D-shape and it comprises a base or skirt portion 105a of somewhat'the same con-' figuration as the upper surface of the cover shell 100' and a pair of somewhat vertical posts 1055 and .1050 interconnected at the top by a hand grip portion 105a. The skirt 105a which substantially covers the top of'the' cover shell 100 functions to shield the hand of the'operator from radiated heat and, hence, provides for comfortable and eflicient operation of the iron. The por tions 105a, 10 5b, 1050 and 105d are molded as a onepiece construction. The rear post 1050 is hollow to.de' fine a relatively large chamber 109, best shown in Fig. .2 of the drawings. At the rear of this chamber there are formed a pair of enlarged bosses 105e, best shown in Fig. 3 of the drawings, disposed on opposite sides of the iron'and each including a tapped opening or a tapped insert molded therein for the purpose of receiving the fastening screws 104 in order to attach the rear of the handle 105 to the unitary support bracket 57 and simultaneously to secure the rear of the cover shell 100 thereto. The lower portion of the enlarged bosses 105e prefer-' ably engage the top of the shell 100'in order to maintain the skirt 105a of the handle 105 out of engagement with the cover shell 100 thereby to minimize the heat transfer between the cover shell and the handle.

To provide an opening for the passage of an electricalcord 112 having the conventional plug connector 112a for supplying power for energizing the heating element 11, there is provided an opening through the wall of the handle 105 defining the chamber 109, as best shown in Fig. 3 of the drawings. As there illustrated, aconven-= tional two-conductor power cord 112 enters the chamber- 109 through the opening 110 and the two conductors 112b and-112d thereof are electricallyconnected-"by ten minal screws 113 and 114 to the conductors 84a and 86a, respectively. The power cord 112 is provided with suitable strain relief means of the type disclosed and clarned in the copending Jepson application, Serial No. 468,454, filed November 12, 1954, and assigned to the same assignee as the present application. Briefly, this strain relief means comprises a helical spring 116 disposed concentrically with the cord 112, and including a plurality of enlarged turns 116a which are of sufiicient diameter to prevent them from entering the opening 110 in the handle 105 of the pressing iron 9. The helical spring 116 is also provided at the end thereof most adjacent the opening 110 with a plurality of turns 11617 of sufiiciently small diameter to enter the opening 110. These turns of reduced diameter terminate in a hooked portion 116c adapted to engage a cord clip 117 secured to the power cord 112. Specifically, the cord clip 117 may comprise a sheet metal stamping having a cylindrical portion 117a clamped to the cord 112 after it has been inserted through the opening 110. This cord clip has a lateral projection 117b extending downwardly therefrom, as viewed in Fig. 3 of the drawings, and another somewhat T-shaped projection 1170 extending upwardly therefrom. The walls of the chamber 109 adjacent the opening 110 are provided with a pair of spaced slots 109a. and best shown in Fig. 2 of the drawings, the slot 109a being disposed above the opening 110, as viewed in Fig. 2, and the slot 109!) being disposed below that opening. The hook-shaped portion 1160 of the helical spring 116 is adapted to engage the T-shaped extension 117c which is accomplished by placing the spring 116 under tension and performing a sort of threading operation in order to insert it into position, so that the turns of large diameter 116a are pulled against the sloping side edges delineating the opening 110, as clearly shown in Fig. 3 of the drawings. Thus, the extension 117b of the cord clip 117 is forced into the recess 10% and the T-shaped projection 117i: is pressed against the chamber wall with the result that these portions engage the walls of the chamber 109 surrounding the opening 110 and provide an excellent strain relief. The inherent force of the coiled spring 116 maintains the hook-shaped portion 116:: in engagement with the projection 1170. At the same time the cord may readily be removed by merely rotating it in a direction to unhook the hook-shaped portion 1160 from the projection 117a, whereupon the spring 116 can be slipped along the cord and the cord can be removed by removing the cord clip 117.

The front post 1051; of the handle 105 defines two more or less vertically extending chambers 119 and 120 separated by a wall portion 105i integral with the handle 105. The top of these chambers is defined by a flat generally circular shelf 105 more or less defining the top of the post 105k. The chamber 119 which is toward the rear of the post 1051) accommodates an elongated temperature control rod 122 defining a cam follower which extends through this chamber and through a relatively small opening 123 defined in the flat shelf 105g. The chamber 120 which is in front of the chamber 119 is of circular cross section and arranged to have the lower portion thereof be in alignment with the opening 101 in the cover shell 100 and consequently in alignment with the opening 46 in the top wall 42 of the water reservoir 40.

In order to provide means for securing the front of the handle 105 to the water reservoir 40, with the reservoir 40 connected to the chamber 120 with an effective seal to prevent the flow of water except between chamber 120 and reservoir 40, the lower opening to chamber 105 which is slightly larger in diameter than the lip 47 of reservoir 40 is provided with an integral annular ridge 105h surrounding the chamber opening. In addition, the opening 101 in cover shell 100 is preferably surrounded at least in part by a mounting ring 125 extending for approximately 240 degrees around the op n ng- The shell 100 and, hence, also relative to the reservoir 40,-

since lip 47 is receivable Within the opening 101 in the cover shell 100.

For the purpose of fastening the front of the handle 105 to the remainder of the pressing iron, the rear being secured by screws 104 described above, there is provided a very simple means of fastening which secures the handle to the tank 40. As illustrated in the drawings, a generally U-shaped clamp 130 is employed formed as a stamping from sheet metal. The bight of the clamp 130 comprises a somewhat circular portion 130a having a tapped opening defined in its center. The legs 13% of the clamp 130 each terminate in an outwardly directed hooked portion 130a adapted to engage the annular indentation 47a surrounding the opening 46 in the top of the water reservoir 40. These legs are resilient and spread apart more than the diameter of the opening 46 in reservoir 40. By squeezing the legs 1301) together, however, the clamp 130 may readily be inserted into the opening 46, whereupon the resilience of the legs will cause them to spread apart to the maximum extent permitted by opening 46, which results in the hooked portions engaging the annular indentation 47a surrounding the opening 46, as clearly shown in Fig. 6 of the drawings. The hollow mounting ring partially surrounding the opening 46 serves to position the handle 105 relative to the cover shell 100, and since the handle does not touch the shell except in very small areas, there is a further minimization of heat transfer therebetween. Furthermore, this mounting ring 125 cooperates with the annular ridge 105): to prevent lateral movement of the handle 105 relative to the cover shell 100. To complete the seal between chamber 120 and reservoir 40, there is provided an annular gasket 131, preferably formed of silicone rubber, which is interposed between the adjacent surfaces of the water reservoir 40, the cover shell 100 and the handle 105. To this end, the gasket 131 is assembled concentric with the annular lip 47 on the water reservoir 40 and in engagement with the deformation surrounding the opening 101 in the cover shell 100. As clearly indicated in Figs. 2 and 6 of the drawings, the gasket 131 includes a flat upper surface portion bearing against the annular ridge 10511 of the handle, while the sides and bottom thereof sealingly engage the boundaries of the opening 101 in the cover shell 100 with the lip 47 on the water reservoir 40. The platform 105g is provided with an opening to receive a threaded hollow fastening means 132 which is capable of threadedly engaging the tapped opening in the bight portion a of the clamp 130 whereby the front of the handle 105 may be firmly secured to the reservoir '40 and the gasket 131 is compressed into sealing engagement with the handle 105 and reservoir 40 to insure that water is confined to the reservoir 40 and the chamber 120.

For the purpose of providing a simple means for filling the reservoir 40 with water or removing water'from the reservoir, there is provided a filler opening 135 in the front post 10515 of the handle 105, which opening leads into the chamber 120. As illustrated in Fig. 1 of the drawings, this opening is of generally rectangular configuration, but, obviously, may have any shape. By providing this opening 135 at the front of the handle 105, it will be apparent that when the iron is placed on its heel in the conventional fashion, resting on the support provided by the rear of the shell 100 and a protrusion 105 at the rear of the handle 105, the opening 135 will e at t e uppermost portion of the iron, so that the reservoir 40 can readily be filled with water through this opening. Preferably, the water employed for conversion into steam should be distilled water, whereby no residue is likely to collect in the water inlet or flow control valve 22 as would be the case if water from sources heavy in mineral content, such as some tap water, were employed. When the iron rests on the sole plate as shown in Fig. 1 of the drawings, the filler opening 135 is, of course, above the level of the liquid in the reservoir and the baflle 56 described above prevents any water from splashing out of the opening 135 during a conventional ironing operation. From the description, it will be apparent that there has been provided a handle with a somewhat L-shaped passageway therein, best shown in Fig. 2 of the drawings. The lower end of this passageway is maintained in sealed relationship with the means defining the opening 46. Thus, it is unnecessary to employ a riser or steam dome connected to the reservoir through which water may be supplied for filling purposes as was the case with prior art arrangements.

It will be appreciated that pressing irons today are used to iron a wide variety of materials such as the new synthetic materials, silk, wool, cotton, linen and the like, all of which require different temperatures for best ironing thereof. For example, rayon requires a much lower ironing temperature than does linen. It is for that reason that means are provided selectively to control the temperature at which the pressing iron 9 operates. To this end means are provided for controlling the position of the lever 90 described above which is engageable by the vertically movable temperature control rod or cam follower 122. It will be appreciated that if the cam follower 122 is moved in a downward direction by some control means, it will lower the temperature setting of the iron, and, of course, if the cam follower 122 is permitted to be moved upwardly in the direction of the resultant biasing forces of the resilient arms 82 and 87, contact 76 will be moved downwardly and, hence, will increase the temperature setting of the iron.

For the purpose of selectively moving the cam follower 122 downwardly or permitting it to be biased upwardly to a greater or lesser extent, there is provided, in accordance with the present invention, a temperature control cam generally designated as 138. This cam 138 is a disk of somewhat circular configuration having an opening at the center for pivotally mounting this cam on the platform 105g, .as best shown in Figs. 2, 6 and 8 of the drawings. This cam is supported for pivotal movement on the platform 105g by the hollow fastening means 132 referred to above, which hollow fastening means is provided with an enlarged integral head portion 132a and a small depending circular portion defining a shoulder 132b of a diameter to be received within the pivot opening in the cam 138. There is preferably also provided a resilient washer 139 interposed between the pivotal cam 138 and the head 132a of the hollow fastening means 132. Thus, the hollow fastening means also performs a plurality of functions. It provides a pivot for the cam 138; it provides a fastening means for securing the handle 105 to the clamp 130; and it provides a passageway therethrough designated by the reference numeral 140 for the needle valve element 50.

The temperature control cam 138 preferably comprises a stamping, the major portion of which is a fiat disk which rests upon the platform 105g of the handle 105. However, the periphery of the cam 138 is deformed throughout an arc in excess of 180" so as to provide on the underside thereof a constant rise cam surface 138a. This cam surface extends over the opening 123 defined in the platform 105g so as to be engageable with means associated with the vertically movable cam follower 122.

To provide for vertical movement of the elongated temperature control rod or cam follower 122 upon rotation of the temperature control cam 138, and to permit calibration in a simple manner, there is provided a cam follower adjusting nut '142 suitably secured to the upper end of rod 122 so as to engage with the cam surface 138a of the temperature control cam 13%. To facilitate the assembly of the cam follower nut 142 upon the upper end of the elongated temperature control rod 122, the latter is provided with a cylindrical portion at its upper end, a portion of which is externally threaded as indicated at 122a. The lower portion ofthe elongated operating rod 122 is of rectangular cross section, as mentioned above, and includes an offset portion 122 to permit the passage of the lower portion of the lever through the passageway 44a defined by the tubular member 44 in the water reservoir 40. The rectangular opening defined by the flange 44b of the tubular member 44 is dimensional to receive the rectangularly shaped lower end of the cam follower 122 in order to prevent rotation thereof when calibrating the temperature control means by manipulating the nut 142 mounted thereon. In order that the adjusting nut 142 may remain fixed at any adjustable position on the end of the cam follower 122, the adjusting nut is preferably provided at its lower end with a longitudinally extending saw cut so that the split ends may be biased together firmly to grip the threaded end 122a of the cam follower 122. When the cam follower 122 is assembled in position, rotation of the cam 138 will cause the cam follower 122 to move downwardly for one direction of rotation and permit it to move upwardly under the resultant bias of the resilient means 82 and 87 supporting the switch contacts 77 and 76, respectively, for the other direction of rotation. It will also be appreciated that by virtue of the shoulder 132!) on the hollow fastening means 132 and the resilient Washer 139, the cam 138 will remain positioned at any place where it is set.

In order to permit manual actuation of the cam 138 in a simple manner, it is provided with an integral extension 138b to which is attached a suitable manually actuatable control knob 143. This control knob 143 extends beyond the confines of the platform g, which has a circular configuration at the front of the iron to permit ready manipulation of the cam 138.

An important feature of the present invention resides in the ability to calibrate the temperature setting at the factory or elsewhere when the iron is completely assembled. To this end the adjusting nut 142, which is provided with a somewhat rounded upper end for engagement with the cam surface 1380/, includes at the center thereof a longitudinally extending hexagonal opening 14% for receiving a conventional Allen wrench or the like. Moreover, the cam 138 is provided at either end of the cam surface 138a with a pair of openings 144 and 145, which openings can be moved into alignment with the longitudinal hexagonal opening 142]; defined within the adjusting nut 142. These openings 144 and 145 are sufiiciently large so that when moved into alignment with the hexagonal opening 14211 they will permit a Wrench to be inserted therein. Likewise, there are provided suitable aligned openings 147 and 148 in portions of the handle 105 overlying the platform 105g so that an Allen wrench may readily be inserted through these openings 147 and 148 to engage the adjusting nut 142.

In order to enclose the portions of the temperature control mechanism described above and of the flow control device to be described hereinafter, and, in addition, to provide suitable indicia for indicating the position of the knob 143 of the temperature control cam 138, there is provided a temperature dial 149 which is shaped so as to provide an enclosure for the platform 105g and a continuation of the hand grip portion 105d of the handle to cause it to blend smoothly with the forward post portion 105]) of the handle. Consequently, the temperature dial 149 is somewhat in the shape of a quarter of a hollow sphere including a projection 149a extending rearwardly into the handle. Preferably a recess 150 is defined in the forward part of the hand grip portion 105 immediately beneath the opening 147 and above a ledge 105k containingthe opening 148. The projection 149a of the temperature dial then extends into the recess 150. To secure the temperature dial 149 in position with the projection 149a within the recess 151}, there is provided a hollow cap rivet 151 insertable into the opening 147 and extending into a suitable opening defined within the projection 14% and aligned with the opening 147 when the temperature dial 149 is properly positioned Within the handle. The cap rivet 151 is hollow so that a suitable Allen wrench may still be inserted through the hollow rivet to adjust the cam follower adjusting nut 142. However, to insure that the cap rivet 151 does not come out and thus release the temperature dial 149, the former is split at the lower end to provide a plurality of legs and a coaxial plug 152 is inserted into the center of the cap rivet 151 to spread the legs thereof and hold the cap rivet in position. Preferably, the opening in the temperature dial projection 149a is larger at the bottom so that the legs of the cap rivet 151 may expand and thus firmly lock the cap rivet in position when the coaxial plug is inserted therein. In the disassembly of the iron the plug 152 may be pushed downwardly out of the cap rivet 151, whereupon the cap rivet is readily removable and the coaxial plug 152 can be recovered when the dial 149 is removed. 1

When assembled to the iron, the temperature dial 149 leaves a narrow space or arcuate slot 153 between the bottom thereof and the platform 105g to permit movement of the extension 1381: and rotation of the cam 138. Preferably, the temperature dial 149 is provided with a skirt portion 149]; overlying the knob 143, on which skirt portion suitable indicia may be provided such as an off indication and an indication of the various kinds of material which Will properly be ironed by the pressing iron when the knob is set in the position indicated for the particular material. A steam setting is also preferably provided. As illustrated in the drawings, this skirt is provided with the following indicia starting from the Off position of knob 143: Off-Rayon, Silk," Steam, Wool, Cotton, Linen.

T provide for selective control of the flow of water from the reservoir 40 to the steam generating chamber 18 in order to effect operation of the iron of the present invention, either as a steam iron or as a dry iron, there is provided a suitable flow control mechanism for controlling the valve 22. The flow control mechanism comprises the needle valve element 50, which has a lower end of somewhat conical shape engageable with the conical valve seat 54. By raising and lowering the needle valve element 50, control of the water flow through metering orifice 51 is obtained. The valve is closed when the conically shaped lower end engages valve seat 54, thus preventing the passage of water from the reservoir 40 to the steam generating chamber 18. When the needle valve element 50 is in its raised position, it allows water to flow along the seating portion 54 of the valve and through the metering orifice 51. To clean the metering orifice 51, there is provided a cleaning pin 154 secured to the lower end of the needle valve element 50. This pin 154 on each closure of the valve 30 extends into the metering orifice 51, thereby removing any lint or accumulation from the steam formation. Preferably, this pin 154 is inserted into an axial bore defined within the lower end of the needle valve element 50 and secured therein by deforming the wall of the element 50, as indicated at 50a.

For the purpose of finger tip control of the needle valve element 50, it extends through the chamber 120 and through the opening in the hollow fastening means 132, whereby the upper end thereof is disposed within the chamber defined by the dial member 149. The upper end of needle valve element 50 is bifurcated to receive an actuating lever 155, which is pivoted thereto by a pivot member 156. This lever 155 extends through an elongated slot 149,1 defined in the temperature dial 149. Se-

cured to the free end of the lever is a manual control knob 157. Preferably, the temperature dial 149 is provided with a recess 1490 having at its center the slot 149;. This recess is wide enough to accommodate the knob 157, which is movable from one end of the recess to the other. The recess rises from one end to the other and is provided with a knob depression 149d at the upper end. The location of this knob depression 149d relative to the lever 155 and the needle valve element is such that when the knob 157 is in depression 14911, the water control valve 22 is open, as shown in solid lines in Figs. 2 and 6 of the drawings. On the other hand, when the knob 157 is in the dotted line position of Fig. 2, the water control valve 22 is closed.

As illustrated in the drawings, the needle valve element 50 is normally urged in a downward direction, as viewed in Figs. 2 and 6 of the drawings, in order to close the flow'control valve 22 by biasing means indicated as comprising a lower washer 159' surrounding the needle valve element 50, a valve spring 160, a non-flexible washer 161, and an upper resilient washer 162. The downward movement of the lower washer 159 along the needle valve element 50 is limited by deformed portions 50b extending laterally and outwardly from the needle valve element 56. The upper washer 162 engages the lower surface of the hollow fastening means 132, with the result that the valve spring 160 is normally compressed between the washers 159 and 162 and, therefore, the valve element 50 is normally urged in a downward direction to prevent the flow of water from the reservoir 40 to the steam generating chamber 18. When it is desired to operate the iron 9 of the present invention as a steam iron, the knob 157 attached to lever 156 is moved to the solid line position indicated in Fig. 2 of the drawings, whereupon the knob 157 rests within the knob depression 149d defined at the upper extremity of the recess 149a, and the needle valve element 50 is raised against the action of the valve spring 160 to induce a flow of water from the reservoir 40 to the steam generating chamber 18, as shown in Fig. 6 of the drawings. In order to provide for an indication of the position of the knob 157 of the flow control mechanism, the temperature dial 149 may be provided with suitable indicia such as Steam on and Steam 011 along the slot 149 It will be understood that the needle valve element 50 may be biased to the open position, if desired, instead of to the closed position, as illustrated. The illustrated arrangement is believed to be quite superior, however, since at least two distinct advantages occur as a result of having spring 160 bias the needle valve element 50 to the closed position. First, the spring 160 provides a safety valve action so that if the openings in the sole plate become blocked, steam pressure may be released by merely forcing valve element 50 upwardly against the biasing force of spring 1611. Secondly, the spring 160, acting in this direction, permits wide manufacturing tolerances with respect to the distance between the seating portion of the valve element and the manual means for locking the valve in the nonbiased position. If the valve were biased to the open position, accurate machining of the element and seat would be necessary to insure that the manual means can lock the valve in a truly closed position.

From the foregoing explanation it will be observed that the temperature control cam 138 and the elements associated therewith together with the flow control mechanism are operated with facility by virtue of the finger tip controls provided at closely adjacent positions near the top and front of the handle 105. Thus, these elements are located in the coolest area of the handle 105, with the result that the problems incident to galling of the cam surface or other related problems resulting from excess heat are avoided.

Moreover, it will be observed that the location of a major portion of the switch assembly 70 to the rear of the sole plate provides for more effective utilization of'the space between the water reservoir and the sole plate and, hence, eliminates the bulky appearance of the iron. It further provides for the location of the switch assembly as far as possible from the steam generating chamber, thus isolating this assembly from the adverse effects of temperature cooling as a result of steam formation. If desired, an insulating sheet 163 having openings for conductors 84a and 86a is provided (Fig. 2) to insulate the electrical current from other parts of the 11011.

In view of the detailed description included above, the operation of the steam and dry iron of the present invention will readily be understood by those skilled in the art and no further discussion thereof is included here- .with.

While there has been shown and described a particular embodiment of the present invention, it willbe apparent to those skilled in the art that various modifications may be made without departing from the invention in its broader aspects, and it is, therefore, aimed in the appended claims to cover all such changes and modifications as fall within the true spirit and scope of the present invention.

What is desired to be secured by Letters Patent of the United States is:

1. In an iron, the combination of a sole plate, a handle including means defining a relatively small opening therein, electric heating means for heating said sole plate, a thermal control device responsive to the temperature of said sole plate for controlling said heating means, manually operated means including a cam and a cam follower for adjusting said thermal control device to alter the temperature of said sole plate, said manually operated means including an operating member, an operating knob carried on said operating member and adjustable to different positions, means for indicating the different positions to which said knob is adjusted, an adjustable means including said cam follower for calibrating said thermal control device in order to effect substantial correlation between the temperature of the sole plate and the indications provided by said indicating means, said cam including at least one opening therein which may be selectively moved into substantial alignment with said relatively small opening in said handle in order to permit the insertion of an adjusting tool through the aligned openings and into operative engagement with said cam follower.

2. The pressing iron of claim 1 wherein said cam follower is a vertically disposed rod having the upper portion extending into a recess defined in said handle.

3. The pressing iron of claim 1 wherein a steam generating chamber and a water reservoir are associated with said sole plate to provide a steam iron, and said cam follower isa vertically disposed relatively slender rod extending through a small passageway defined in said reservoir, said passageway being only slightly larger in cross section than said slender rod.

4. A steam iron comprising a sole plate, heating means for said sole plate, means :defining a steam generator in said sole plate in intimate heat exchange relationship with said heating means, a water reservoir, valve means for controlling the flow of water from said reservoir to said steam generating chamber including an axially movable elongated valve element movable between open and closed positions, means for biasing said valve element to.

one of said two positions, a link pivotally connected to one end of said valve element, means on said handle defining a cam surface, and means on said link engageable with said cam surface whereby pivotal movement of said link relative to said valve element moves said valve element to the other of said positions against the force of said biasing means.

5. The steam iron of claim 4 wherein said valve element is biased to the closed position.

6. The steam iron of claim 4 wherein said cam surface is at the upper front of the handle and wherein said means on said link is a manually actuable knob.

7. In a pressing iron, the combination of a sole plate, a handle for said iron including means defining a relatively fiat surface thereon, means for heating said sole plate, a thermal control device responsive to the tempera ture of said sole plate for controlling said heating means, manually operated means for selectively adjusting said thermal control device to alter the temperature of said sole plate, said manually operated means including a cam and a cam follower, said cam having a relatively flat portion resting upon the flat surface of said handle, means supporting said cam for pivotal movement upon said flat surface, said cam also including a camming portion in engagement with said cam follower, and means interconnecting said cam follower and thermal control device whereby the temperature of said iron is controlled inresponse to the pivotal position of said cam.

8. A pressing iron comprising a sole plate, a handle including means defining a relatively flat horizontal surface thereon, means for heating said sole plate, a thermal control device responsive to the temperature of said sole plate for controlling said heating means, said thermal control device including at least two relatively movable contacts and means resiliently supporting said contacts for relative movement, manually operated means for selectively adjusting said thermal control device to alter the temperature of said sole plate, said manually operated means including a somewhat circular cam and a cam follower, said cam having a relatively flat central portion resting upon the flat surface of said handle,-means supporting said cam for pivotal movement upon said flat surface, said oam having a sloping portion along a substantial portion of its periphery comprising a camming surface'in engagement with said cam follower, and means interconnecting said cam follower and said contacts, the means resiliently supporting said contacts normally urging said cam follower into engagement with the oamming surface of the cam.

9. In a pressing iron, the combination of a sole plate and a handle, means defining a recessed portion in said handle, means defining a small chamber disposed in said handle near said recessed portion, said handle further including means defining an opening extending from said chamber to the exterior surface of the handle, the longitudinal axis of said opening being disposed perpendicularly to the ironing surface of said sole plate, a closure member for substantially enclosing the recessed portion of said handle, said closure member being constantly in a fixed position relative to said handle during normal use and operation of said pressing iron, said closure member including a projection extending into said chamber, means defining an opening in said projection capable of being disposed in alignment 'with the opening in said handle, and detachable fastening means extending through the aligned openings to hold said closure member in assembled relationship with said handle.

10. A steam iron comprising a sole plate, heating means for said sole plate, means defining a steam generator in said sole plate in intimate heat exchange relationship with said heating means, a water reservoir, valve means for controlling the fiow of water from said reservoir to said steam generating chamber, a handle secured to said sole plate, means on said handle defining an inclined surface, a chamber defined beneath said surface, said handle having a slot communicating with said chamber and extending along said inclined surface, said valve means including a vertically movable valve element having one end thereof extending into said chamber, an arm having one end connected to said one end of said element with the other end of said arm extending through said slot, and a manually actuable knob secured to said other end of said arm for moving said arm along said slot with said knob moving along said inclined surface whereby said valve means is closed when said knob .is

23 disposed at one end of said inclined surface and open when disposed at the other end of said inclined surface.

11. The steam iron of claim wherein resilient means are provided to urge said valve element to the closed position, and wherein at least the end of said inclined surface corresponding to the open position of said valve element is provided with seating means for said knob to retain said knob therein and hold said valve element open against the force of said biasing means.

12. The steam iron of claim 10 wherein said slot is at the upper front of said handle and said inclined surface is defined within a recess extending along said handle with said slot within said recess, said recess having a width sufficient to receive said knob, said recess including a depression therein at the upper end thereof to hold said knob therein when moved to that end of said recess.

13. In a steam iron, the. combination of a sole plate, heating means for said sole plate, means in said sole plate defining a steam generating chamber, a water reservoir,

means for securing said water reservoir to said sole plate, valve means for controlling the flow of water from said reservoir to said steam generating chamber, a cover shell for said iron, a supporting member Secured "to .the rear end of said sole plate, a handle for said iron including means defining a recess near the forward end thereof, single fastening means for securing both said cover shell and said handle to said supporting member, and means secured to said handle within said recess for holding the forwardly disposed portions of said handle, said cover shell and said reservoir in assembled relationship.

14. The steam iron of claim 13 wherein said last mentioned means comprises a member engaging the edges of the filler opening for said reservoir.

15. The steam iron of claim 13 wherein said water reservoir has a filler opening and said last mentioned means includes a U-shaped member with hooks provided at the ends of the arms thereof engageable with the edges of said filler opening.

16. A steam iron comprising a sole plate and heating means therefor, means defining a steam generating chamher in said sole plate, a water reservoir, means for supporting said water reservoir near the front end of said sole plate, a cover shell for said iron, a supporting member secured to the rear end of said sole plate for supporting said cover shell, said supporting member including means in engagement with the end of said reservoir disposed towards the rear of the iron thereby to hold the rearwardly disposed end of the reservoir in elevated position above the sole plate, a handle for said iron including means defining a recess near the forward end thereof, said reservoir including means defining an opening in its upper surface near the forward end thereof, single fastening means for securing both said cover shell and said handle to said supporting member, and means including a clamp carried by said handle within said recess and having spaced, resilient leg portions fitting within the opening in said reservoir to hold the forwardly disposed portions of said handle, said cover shell and said reservoir in assembled relationship.

17. In a combined steam and dry iron, the combination of a sole plate, a handle including means defining a supporting surface thereon, means for heating said sole plate, a thermal control device responsive to the temperature of said sole plate for controlling said heating means, manually operated means for adjusting said thermal control device to alter the temperature of said sole plate, said manually operated means including an operating member carried upon said supporting surface of said handle, a hollow pivot member supporting said operating member for pivotal movement upon said supporting surface, means defining a steam generating chamber in said sole plate, a water reservoir secured to said sole plate, valve means for controlling the flow of water from said reservoir to said steam generating chamber and including a valve element having a portion extending through said 24 hollow :pivot member, manuallyoperable means secured to :said portion for moving said valve element .to control the "flow of water between said reservoir and said steam generating chamber, and means including aclamp secured to said handle by said hollow pivot member forholding said handle and said reservoir in assembled relationship.

18. Apressing iron including a sole plate and heating means therefor, a handle secured to said sole plate including means defining a substantially flat supporting wall thereon, a thermal control device responsive to the temperature of said sole plate for controlling said heating means, manually operated means for selectively adjusting said thermal control device to alter the temperature of said sole plate, said manually operated means including a cam pivotally mounted upon said supporting wall, a pivot member extending through said cam and said wall to support said cam for pivotal movement upon said wall, a cover shell for said iron attached to said sole plate, and means including a clamp secured tosaid handle by said pivot member for holding said cover shell and said handle in assembled relationship.

19. In a combined steam and dry iron, the combination of a sole plate including means defining a steam generating chamber therein a handle including means defining a recess therein, a temperature dial cooperating with said handle substantially to enclose said recess and including means defining an opening therein, means for detachably securing said dial to said handle, heating means for said iron, a thermal control device for controlling said heating means, means for adjusting said thermal control device to control the operating temperature of the iron, said last named means including an operating member positioned within said recess and a control knob selectively movable to different positions to adjust the operation of said thermal control device, in dicia on said dial disposed adjacent the path of movement of said knob to indicate the different positions 0c,- cupied by said knob, valve means for controlling flow of water to said steam generating chamber, and including a manually operable actuating element extending through the opening in said dial, and additional indicia on said dial cooperating with said manually operable element.

20. A steam iron comprising a sole plate, a steam generating chamber in said sole plate, a multilayer cover for said steam generating chamber, said layers comprising an outer rigid layer of metal, an intermediate layer of resilient heat resisting material and an inner layer of metallic foil, each of said layers being coextensive with the other layers, and a member for holding the different layers of said cover as a unitary assembly even when said cover isremoved from said steam generating chamber, said member also comprising the valve body of a valve for controlling the flow of water to said steam generating chamber.

References Cited in the file of this patent UNITED STATES PATENTS Re. 24,181 .Tepson July 17, 1956 2,457,185 Sparklin Dec. 28, 1948 2,501,028 Charland Mar. 21, 1950 2,557,732 Finlayson June 19, 1951 2,588,747 Morton Mar. 11, 1952 2,608,773 Finlayson Sept. 2, 1952 2,637,126 Fitzsimrnons May 5, 1953 2,662,316 Johnson Dec. 15, 1953 2,668,378 Vance Feb. 9, 1954 2,680,312 Parr June 8, 1954 2,681,521 Finlayson June 22, 1954 2,719,371 Brace Oct. 4, 1955 2,724,197 Beach Nov. 22, 1955 2,755,574 Herman July 24, 1956 2,786,288 Beach Mar. 26, 1957 2,825,157 Kistner Mar. 4, 1958 sutm 

